Method for smelterless recycling of lead acid batteries

ABSTRACT

Lead from lead acid battery scrap is recovered in two separate production streams as clean grid lead and as high-purity lead without smelting. In preferred aspects, lead recovery is performed in a continuous process that uses an aqueous electroprocessing solvent and electro-refining and spent electroprocessing solvent can be recycled to the recovery process.

This application claims priority to U.S. provisional application with the Ser. No. 61/905,941, which was filed 19 Nov. 2013.

FIELD OF THE INVENTION

The field of the invention is recycling of lead acid batteries, especially as it relates to devices and methods that utilize aqueous solutions and do not require smelting and that can be performed in continuous fashion.

BACKGROUND OF THE INVENTION

The background description includes information that may be useful in understanding the present invention. It is not an admission that any of the information provided herein is prior art or relevant to the presently claimed invention, or that any publication specifically or implicitly referenced is prior art.

Lead acid batteries (LABs) are the single largest class of batteries used today. They are essential for applications ranging from starting automobile engines, providing emergency back-up power for data centers, and powering industrial and recreational vehicles such as fork lift trucks and golf carts. Unlike any other battery type, LABs are almost 100% recycled and this feature puts lead as the single most recycled commodity. While LAB production is increasing at an average rate of about 5% per year globally, production of new lead from ore is becoming increasingly difficult as lead rich ore deposits as depleted. Not surprisingly, new and more efficient methods for lead recycling are urgently needed.

Unfortunately, all or almost all of the current lead recycling from LABs is still based on lead smelting technology, originally developed over 2000 years ago to produce lead from ore bodies. Lead smelting is a pyro-metallurgical process in which lead, lead oxides, and other lead compounds are heated to about 1600° F. and then mixed with various reducing agents to remove oxides, sulfates, and other non-lead materials. Prior Art FIG. 1 depicts a typical smelting operation starting with ground up LAB materials.

Unfortunately, lead smelting is a highly polluting process, generating significant airborne waste (e.g., lead dust, CO2, arsenic, SO2), solid waste (lead containing slag), and liquid waste (e.g., sulfuric acid, arsenic salts), and pollution issues have forced the closure of many smelters in the US and other Western countries. Migration and expansion of smelters in less regulated countries has resulted in large scale pollution and high levels of human lead contamination.

To complicate matters, obtaining permits for lead smelters has become increasingly difficult, and smelting plants are generally expensive to build and operate. Consequently, profitable operation of smelters is a function of scale. As such, there is a drive towards larger and more centralized smelters, which is at odds with the logistics of the LAB industry that favors distributed recycling and production located close to concentrations of LAB use. As a result, only the largest LAB producing companies have been able to justify and operate smelters while other companies rely on secondary lead producers to recycle their batteries and supply them with lead. This can make it difficult for LAB producers to meet increasingly stringent requirements for “cradle to grave” control of their products, such as the international standard ISO 14000.

On a more technical level, it should be appreciated that lead smelting was developed to produce lead from lead ore (primarily Galena or lead sulfide). However, the chemistry of recycled lead acid batteries is vastly different to the chemistry of lead smelting of ores. As such lead smelting is a fundamentally inefficient process for lead recycling.

Various efforts have been made to move away from smelting operations and to use more environmentally friendly solutions. For example, U.S. Pat. No. 4,927,510 teaches recovering in pure metal form substantially all lead from battery sludge after a desulfurization process. All publications identified herein are incorporated by reference to the same extent as if each individual publication or patent application were specifically and individually indicated to be incorporated by reference. Where a definition or use of a term in an incorporated reference is inconsistent or contrary to the definition of that term provided herein, the definition of that term provided herein applies and the definition of that term in the reference does not apply. Unfortunately, the '510 patent still requires use of a fluorine containing electrolyte, which is equally problematic.

To overcome some of the difficulties associated with fluorine containing electrolyte, desulfurized lead active materials have been dissolved in methane sulfonic acid as described in U.S. Pat. No. 5,262,020 and U.S. Pat. No. 5,520,794. However, as lead sulfate is rather poorly soluble in methane sulfonic acid, upstream pre-desulfurization is still necessary and residual insoluble materials typically reduced the overall yield to an economically unattractive process. To improve at least some of the aspects associated with lead sulfate, oxygen and/or ferric methane sulfonate can be added as described in WO 2014/076544, or mixed oxides can be produced as taught in WO 2014/076547. However, despite the improved yield, several disadvantages nevertheless remain. Among other things, solvent reuse in these processes often requires additional effort, and residual sulfates are still lost as waste product. Moreover, during process upset conditions or power outage (which is not uncommon in electrolytic lead recovery), the plated metallic lead will dissolve back into the electrolyte in conventional electrolytic recovery operations, unless the cathode was removed and the lead peeled off, rendering batch operation at best problematic.

Thus, even though numerous methods for lead recycling are known in the art, all or almost all of them, suffer from one or more disadvantages. Therefore, there is still a need for improved devices and method for smelterless recycling of lead acid batteries, especially in a continuous manner.

SUMMARY OF THE INVENTION

The inventive subject matter is directed to various devices, systems, and methods of lead material processing in which an electroprocessing solvent is used to selectively dissolve the active material lead (e.g., PbO, PbO2 and PbSO4) while cleaning and maintaining the grid lead (e.g., battery grids and lead contacts) in solid form. The dissolved lead is then recovered in an electrolytic cell, preferably in a continuous fashion, while clean solid grid lead is recovered from the lead ion-enriched electroprocessing solvent.

In one aspect of the inventive subject matter, the inventors contemplate a method of processing various lead materials, and especially from lead acid batteries in which the lead materials (e.g., grid lead and active material lead) are contacted with an electroprocessing solvent to so selectively dissolve the active material lead, thereby forming a lead ion-enriched electroprocessing solvent and solid grid lead. In especially preferred aspects of contemplated methods, the electroprocessing solvent is an aqueous solution of an alkane sulfonic acid (e.g., methane sulfonic acid) and a chelator (e.g., EDTA). Once the active material lead is dissolved at least some of the grid lead is removed from the lead ion-enriched electroprocessing solvent and the lead ions in the lead ion-enriched electroprocessing solvent are reduced on a cathode to form high-purity lead and a regenerated electroprocessing solvent.

While not limiting to the inventive subject matter, it is generally preferred that the active material lead has not undergone a desulfurization step, but is directly obtained from lead acid battery scrap. It is further generally preferred that the electroprocessing solvent include the alkane sulfonic acid in an amount of between 5 and 50 wt % and the chelator in an amount of between 0.5 and 20 wt %.

With respect to reduction it is especially preferred that reduction is a continuous process. For example, lead ions are preferably reduced on one portion of the cathode while at least some of the high-purity lead is recovered from another portion of the cathode. Most typically, the lead ions are reduced under conditions that promote formation of a micro- or nanoporous mixed matrix (containing molecular hydrogen and electroprocessing solvent) having a density of less than 5 g/cm3, or a density of less than 3 g/cm3, or a density of less than 1 g/cm3.

While not limiting to the inventive subject matter, the cathode is moved relative to the lead ion-enriched electroprocessing solvent (e.g., as a rotating disk, a rotating cylinder, a rolling conveyor-type belt, or reciprocating plate) during the step of reducing the lead ions. Where desired, it is also contemplated that such methods may include a step of removing sulfate and/or a metal ion other than lead (e.g., tin, silver calcium, arsenic) from the regenerated electroprocessing solvent, and/or a step of using at least some of the regenerated electroprocessing solvent in the step of contacting the lead materials with the electroprocessing solvent. Additionally, it is generally preferred that all process steps are performed such as to allow processing of the lead materials in a continuous fashion.

In another aspect of the inventive subject matter, the inventors contemplate a method of continuously and electrochemically producing high-purity lead from a lead ion-enriched electroprocessing solvent. In such method, a lead ion-enriched electroprocessing solvent is provided and lead ions in the lead ion-enriched electroprocessing solvent are reduced on a cathode to so form adherent high-purity lead and a regenerated electroprocessing solvent. Most typically, the adherent high-purity lead is then removed from one portion of the cathode while lead ions are reduced on another portion of the cathode. In further contemplated aspects, at least some of the regenerated electroprocessing solvent is then contacted with lead materials comprising grid lead and active material lead to so produce at least a portion of the lead ion-enriched electroprocessing solvent.

Such methods will also include a step of dissolving active material lead in an electroprocessing solvent to so form the lead ion-enriched electroprocessing solvent. Most typically, but not necessarily, the active material lead can be used directly from lead acid battery scrap without further processing (e.g., without prior desulfurization). As noted before, it is generally preferred that the lead ion-enriched electroprocessing solvent includes an alkane sulfonic acid (e.g., methane sulfonic acid) in an amount of between 5 and 50 wt % and a chelator (e.g., EDTA) in an amount of between 0.5 and 20 wt %. Where desired, it is contemplated that sulfate and/or a metal ion other than lead is removed from the regenerated electroprocessing solvent

In further contemplated aspects, the cathode is moved relative to the lead ion-enriched electroprocessing solvent during the step of reducing the lead ions, and/or the high-purity lead has a purity of at least 98%, more preferably at least 99%, and most preferably at least 99.5%. Among other options, it is generally preferred that the high-purity lead is only weakly associated with the surface of the cathode and can be readily removed by a harvester surface in a non-peeling manner, and that the harvester surface is positioned proximal to the cathode. Thusly produced high-purity lead will typically be or comprise a micro- or nanoporous mixed matrix having a density of less than 5 g/cm3.

Therefore, and viewed from a different perspective, the inventors also contemplate an electrolyzer for producing high-purity lead from a lead ion-enriched electroprocessing solvent. Most preferably, such electrolyzer will include a cell that contains a lead ion-enriched electroprocessing solvent, an anode and a cathode, both of which are at least partially disposed in the cell to allow contact of the anode and cathode with the lead ion-enriched electroprocessing solvent. It is still further generally preferred that the electrolyzer will further comprise a lead harvester that is positioned proximally to a surface of the cathode and configured to collect weakly associated high-purity lead from the surface of the cathode in a non-peeling manner.

Contemplated electrolyzer may be configured in numerous manners. However, it is typically preferred that the anode and cathode are disposed in the same cell without a separator, that the anode is a titanium anode that is coated with a metal oxide an example of which is ruthenium oxide, and/or that the cathode is an aluminum cathode. Moreover, it is generally preferred that the cathode is configured to move relative to the lead ion-enriched electroprocessing solvent (e.g., configured as a rotating disk shaped cathode, preferably rotatable at a speed that allows formation of weakly associated high-purity lead in a micro- or nanoporous mixed matrix on the disk shaped cathode. Where desired, a harvester surface maybe positioned proximal to the cathode to remove adherent high-purity lead in a non-peeling manner. Additionally, it is contemplated that a solvent conditioning unit (e.g., ion exchange resin, ion selective membrane, precipitation tank) is fluidly coupled to the cell to allow for removal of sulfate and/or a metal ion other than lead from the solvent.

Therefore, in a further aspect of the inventive subject matter, the inventors also contemplate a production intermediate that comprises (a) an aqueous solution containing alkane sulfonic acid in an amount of between 5 and 50 wt % of the solution and a chelator in an amount of between 0.5 and 20 wt % of the solution, and (b) undissolved solid grid lead and dissolved active material lead. Most typically, the alkane sulfonic acid is methane sulfonic acid and is present in an amount of between 15 and 35 wt %, and/or the chelator is EDTA (ethylene diamine tetraacetic acid) and is present in an amount of between 1 and 10 wt %. As noted before, it should be appreciated that the active material lead need not necessarily be desulfirized.

Additionally, the inventors contemplate a lead composition that includes solid lead having a purity of at least 98%6 (more typically at least 99%, most typically at least 99.5%), molecular hydrogen, and an electroprocessing solvent, wherein the solid lead, the hydrogen, and the electroprocessing solvent form a micro- or nanoporous mixed matrix having a density of less than 5 g/cm3, or of less than 5 g/cm3, or of less than 1 g/cm3. Most typically, the electroprocessing solvent comprises an alkane sulfonic acid (e.g., methane sulfonic acid) in an amount of between 5 and 50 wt % of the solvent and a chelator (e.g., EDTA) in an amount of between 0.5 and 20 wt % of the solvent.

Various objects, features, aspects and advantages of the inventive subject matter will become more apparent from the following detailed description of preferred embodiments, along with the accompanying drawing figures in which like numerals represent like components.

BRIEF DESCRIPTION OF THE DRAWING

Prior FIG. 1A is a schematic of a conventional smelting process for ground lead acid battery materials.

FIG. 1B is an exemplary schematic of a smelter-less process for ground lead acid battery materials according to the inventive subject matter.

FIG. 1C is an exemplary schematic of an electrolyzer according to the inventive subject matter.

FIG. 2A is an exemplary experimental set up for a process according to FIG. 1B.

FIG. 2B is a detail view for an electrolyzer with a disc-shaped cathode and a lead product in a micro- or nanoporous mixed matrix.

FIGS. 3A-3C are graphs illustrating current efficiencies (CE) as a function of lead concentration (3A, 3C) and current density (3B) using an electrolyzer according to the inventive subject matter.

DETAILED DESCRIPTION

The inventors have now discovered that lead acid battery materials can be recycled in a conceptually simple, yet effective manner where all lead materials are treated with a multi-functional electroprocessing solvent that helps clean grid lead materials, and especially grids and contacts/bus bars, while at the same time dissolves all active lead materials, including lead oxide and lead sulfate. Moreover, the same solvent can, upon loading with lead ions due to active materials dissolution, be subjected to an electrolysis process that allows continuous production of high-purity lead while regenerating the electroprocessing solvent for a further cycle.

With respect to the continuous lead recovery it should be especially appreciated that heretofore known processes would plate metallic lead from an electrolyte onto a cathode in an acidic solution. During process upset conditions or power outage (which is not uncommon in electrolytic lead recovery), the plated metallic lead would dissolve back into the electrolyte unless the cathode was removed and the lead removed. Still further, conventional electrolytic lead recovery processes deposit or plate lead as a strongly bound film to the cathode, which makes removal of the lead labor intensive. For example, lead can be peeled from the cathode as sheets. However, such sheets have the tendency to break or flake, and lead removal is thus incomplete and/or laborsome. In contrast, the lead recovery using the devices and methods according to the inventive subject matter will allow recovery of high purity lead in a non-peeling manner. For example, the lead product can be removed from the cathode as a non-film material (e.g., as amorphous micro- or nanoporous mixed matrix) using a wiper or scraper (preferably where the scraper does not directly contact the cathode but is in close proximity, e.g., between 0.5 and 5 mm) as a removal tool, which in turn allows continuous removal on one portion of the cathode while reduction is performed at another portion of the cathode.

In particularly preferred aspects of the inventive subject matter, the electroprocessing solvent comprises an alkane sulfonic acid in combination with a chelator, and most preferably methane sulfonic acid and EDTA. The inventors surprisingly discovered that all relevant lead species found in active material lead are effectively and quickly dissolved in MSA (methane sulfonic acid) where the MSA includes substantial quantities of a chelator at an acidic pH (i.e., at a pH equal or less than 7.0, equal or less than 6.0, equal or less than 5.0, equal or less than 4.0, or equal or less than 3.0). For example an aqueous solution of MSA and EDTA did dissolve positive active material (e.g., lead sulfate, and especially tri/tetrabasic lead sulfate; PbSO4.3PbO.H2O/PbSO4.4PbO.H2O) as well as negative active material (e.g., lead oxide ranging from Pb(II) to Pb(IV) and multiple partial oxidation states between them). Moreover, it was observed that under dissolving conditions for the active material lead, grid lead (e.g., metallic lead from contacts, bus bars, lead alloys for battery grids, etc.) is not dissolved but instead cleaned by the electroprocessing solvent. Such finding was particularly unexpected as known processes involving lead dissolution in MSA characterized lead sulfate as being only sparsely soluble in MSA. Therefore, among other benefits of using a chelator (and especially EDTA) in MSA, it should be noted that EDTA synergistically and dramatically enhanced solubility of lead sulfates in MSA. Consequently, it should be recognized that using the electroprocessing solvent of the inventive subject matter, active material lead can be processed without the need for prior desulfurization.

Additionally, the inventors also unexpectedly noted that electroprocessing solvents comprising an alkane sulfonic acid and a chelator, and especially MSA and EDTA, were suitable for electrolytic recovery of lead on a cathode. Notably, such recovery could even be performed in an electrolytic cell without a separator and as such significantly simplified the design of suitable electrolyzers. Such finding was particularly unexpected as prior reports on lead acid batteries having MSA as electrolyte (SLABs) noted that layers of an insoluble form of PbO2 would form on the anode, which effectively shuts down the SLAB battery. Without use of the chelator, and especially EDTA, usefulness of MSA would be limited electrolytic recovery of lead as the insoluble from of PbO2 will be present in at least some scrap materials from LABs.

While EDTA has been used to preferentially dissolve lead salts and to support lead electrochemical plating from solution as described in U.S. Pat. No. 7,368,043, such plating requires a complex and expensive electrochemical cell with a membrane separator to inhibit destruction of the EDTA. Still further, such process also operates at high pH (caustic pH) and it would be impractical to convert all of the active material from a LAB to caustic on a commercial basis. In contrast. EDTA in combination with the MSA at acidic pH not only increased solubility of most lead species, and especially lead sulfates, but also allowed for reduction of ionic lead to an adherent, but not plated form. As used herein, the terms “adherent” or “weakly associated” in conjunction with metallic lead that was formed by reduction of ionic lead refers to a form of lead that is not a coherent film over the surface of the cathode, but that is amorphous and can be wiped off the cathode. In other words, a weakly associated or adherent lead product does not form in a macroscopic dimension intermetallic bonds between the cathode and the lead product and will therefore not form a coherent lead film on the cathode. For example, by observation in most experiments (e.g., see experimental description below), lead formed in a spongy low density layer that was barely attached to the cathode, floated off a static plate cathode, and could be washed off the surface of a rotating cathode if electrolyte circulation is too aggressive. Moreover, the combination of the alkane sulfonic acid (e.g., MSA) and chelator (e.g., EDTA) allowed for stable electrolytic recovery of lead without significant destruction of the alkane sulfonic acid (e.g., MSA) and chelator (e.g., EDTA).

Therefore, it should be appreciated that lead acid batteries and battery materials can be processed as exemplarily depicted in FIG. 1B by first crushing or grinding the battery or battery materials to a relatively small size (e.g., average particle size between 0.1 and 1 cm, or between 1 and 3 cm, or between 3 and 5 cm, or larger, in the largest dimension), followed by removal of plastic parts and battery acid (which can be further recycled or processed). The so obtained lead scrap material will predominantly contain grid lead and active material lead, which is then treated in a container with the electroprocessing solvent to clean the grid lead and to dissolve the active material lead. After a suitable period of lead dissolution (or upon complete dissolution of the active material lead), remaining cleaned solid grid lead can be extracted from the solution, optionally washed, and pressed into lead chips/ingots to so yield grid lead that can be directly reused or further refined. The recitation of ranges of values herein is merely intended to serve as a shorthand method of referring individually to each separate value falling within the range. Unless otherwise indicated herein, each individual value is incorporated into the specification as if it were individually recited herein.

The so obtained lead ion-enriched solution may then be treated to remove other non-lead ions (e.g., zinc, calcium, tin, silver, etc.), which may be performed using a selective ion exchange resin, other selective adsorbent, selective electrodeposition, liquid chromatography and/or precipitation. Of course, it should be recognized that such step may also be performed after electrolytic recovery of lead. Regardless of any optional pre-processing, the lead ion-enriched solution is then fed to an electrolyzer to recover the lead in metallic form. While any type of electrolyzer is generally contemplated, especially preferred electrolyzers will include those without separator or membrane between the cathode and the anode, and with a cathode that moves relative to the electrolyte. After reduction of the lead ions, the process will yield a high-purity lead (i.e., at least 98% purity, or at least 99% purity, or at least 99.5% purity). Where the electrolyzer has one or more moving electrodes, and especially rotating disk electrodes, lead is being deposited as adherent but non-film forming lead.

Surprisingly, the inventors discovered that the so formed lead formed a micro- or nanoporous mixed matrix in which the lead formed micro- or nanometer sized structures (typically needles/wires) that trapped some of the electroprocessing solvent and a substantial quantity of molecular hydrogen (i.e., H2). Most notably, such matrix had a black appearance and a remarkably low bulk density. Indeed, in most of the experimental test runs, the matrix did float on the solvent and had a density of less than 1 g/cm3. Upon pressing the matrix or application of other force, the density increased (e.g., 1-3 g/cm3, or 3-5 g/cm3, or higher) and a metallic silvery sheen appeared.

Additionally, it was unexpectedly observed that the reduced lead ions did not form a tightly bonded film on the cathode, but could be readily removed from the cathode, simply by wiping the cathode with a material to which the lead could adhere (e.g., plastic, lead-film, etc.). Therefore, lead recovery can be performed in a continuous manner. Particularly where a rotating or reciprocating electrode was employed, lead ions could be reduced one part of an electrode or electrode assembly, while metallic lead can be removed from another part of the electrode or electrode assembly.

In yet a further advantageous aspect of the inventive subject matter, it should also be recognized that the electroprocessing solvent can be reused after sufficient quantities of lead had been removed via reduction. Most notably, the inventors discovered that both MSA and EDTA were remarkably stable under the conditions used (see experimental below), and that the spent electroprocessing solvent could be processed by mechanical processing (e.g., filter, centrifuge, hydrocyclone, etc.) to remove any solids, and/or chemical processing (e.g., by precipitation of sulfates, for example, to produce calcium or strontium sulfate), and/or adsorptive processing (e.g., activated charcoal ion exchange resin, etc.). So processed solvent can then be reused in the next cycle of processing lead materials.

With respect to the alkane sulfonic acid it should be appreciated that numerous alkane sulfonic acids are deemed suitable for use herein. However, MSA is especially preferred as this compound is environmentally friendly and stable under electrolytic conditions used. However, other suitable alkane sulfonic acids include ethyl sulfonate, proplyene sulfonate, trifluro methyl sulfonate (triflic acid), sulfamic acid, etc. In most circumstances, the MSA or other alkane sulfonic acid will be present in a significant concentration, typically at least 1-5 wt %, more typically 5-15 wt %, even more typically 25-50 wt %, and most typically between 15 and 35 wt % of the electroprocessing solvent. Thus, suitable concentrations will typically be between 5 and 50 wt %, or between 20 and 30 wt % of the electroprocessing solvent. The pH of the electroprocessing solvent is most preferably acidic as noted above, and most typically between pH 5-7, or between pH 1-3, or between pH 3-5. Viewed form a different perspective, the pH of the electroprocessing solvent will be less than 7, or equal or less than 5, or equal or less than 3.

Similarly, the nature of the chelator may vary considerably. However, it is generally preferred that the chelator is a chelator that is selective or preferential for divalent cations. Therefore, EDTA may be partially or completely replaced by other chelating agents such as NTA (nitrilotriacetic acid), IDA (iminodiacetic acid), DTPA (diethylenetriaminepentaacetic acid), etc. Regardless of the particular type of chelator, it is preferred that the chelator is typically present in an amount of at least 0.1-1 wt %, more typically 1-3 wt %, even more typically 3-10 wt %, and most typically between 2 and 8 wt % of the electroprocessing solvent. Furthermore, it is noted that the chelator may be provided in form of a salt where the chelator has otherwise reduced solubility in acidic solution (e.g., Na2-EDTA). It should be noted that such concentrations may even exceed the solubility limit of the chelator. Suitable solvent are preferably aqueous and will most preferably be prepared from deionized water. However, additional co-solvents are also deemed suitable and include alcohols, various polyols (propylene glycol, polyethylene glycol, etc.), brighteners, etc.

Of course, it should be noted that the particular size/dimensions of the electrolytic cell may vary considerably and that the specific process conditions and operating parameters will at least in part determine the size and volume of the electrolytic cell. In especially preferred aspects, however, the electrolytic cell is operable without the need for a membrane separator. Viewed from another perspective, the cell need not be separated in fluidly distinct catholyte and anolyte compartments. Moreover, it should be appreciated that the electrolytic cell need only be fluidly coupled to the container in which the lead materials are being dissolved and/or cleaned. Where treatment of the electroprocessing solvent is considered, it should be noted that the type of treatment will determine the location of such treatment unit, and that the skilled artisan will be readily appraised of the suitable location. However, preferred locations are those where treatment is performed on the lead ion-enriched solvent or the at least partially depleted solvent. As used herein, and unless the context dictates otherwise, the term “coupled to” is intended to include both direct coupling (in which two elements that are coupled to each other contact each other) and indirect coupling (in which at least one additional element is located between the two elements). Therefore, the terms “coupled to” and “coupled with” are used synonymously.

In other contemplated aspects of the inventive subject matter, and with further respect to the electrodes in the electrolyzer it should be appreciated that numerous electrodes are deemed suitable for use herein. Indeed, it should be noted that all conductive materials are considered suitable for use in conjunction with the teachings herein so long as such materials are compatible with the electrochemical conditions use in the process. Therefore, and among other contemplated materials, suitable anodes include various metals, carbon (typically graphite, glassy carbon, or graphene) anodes, matrices comprising at least one polymer and one form of carbon and especially preferred anodes will be titanium anodes, which may be coated with ruthenium oxide (or other metal oxide). Notably, aluminum has been found not to dissolve in the lead-ion enriched electroprocessing solvent and as such aluminum coated with a conducting and non-passivating material such as ruthenium oxide is contemplated as an anode material. Alternatively Magneli Phase sub-oxides of titanium (of the formula TixO(2x−1) where x is an integer between 4 and 11) have been discovered to be stable anode materials in electrolytes of similar composition to the electroprocessing solvent and are contemplated for use as anode materials and passivation resistant coatings on anodes.

More notably, however, the inventors discovered that the lead recovery process, when using the lead ion-enriched electroprocessing solvent, would lead to the formation of a low density lead composition that included lead at a very high purity and that included some of the solvent and hydrogen produced at the cathode. Most remarkably, most if not all of the so formed lead composition was black in color, did not plate and bond as an electrochemically bound film to the cathode, but floated onto the surface upon moderate to strong agitation of the solvent. When pressed into a smaller volume, the hydrogen and electroprocessing solvent was expelled and the remaining lead returned to a metallic appearance. Unexpectedly, less than 10% (e.g., between 5-9%), more typically less than 7% (e.g., between 2-6%), even more typically less than 5% (e.g., between 1-4%), and most typically less than 3% (e.g., between 0.01-2%) of the total lead formed at the cathode was found as plated and strongly adherent lead on the cathode, while the remainder of the lead remained in the low density form. While not wishing to be bound by any theory or hypothesis, the inventors contemplate that the lead in the low density lead materials formed a micro- or nanoporous mixed matrix comprising micrometer or even nanometer-sized lead filaments to form a porous material in which hydrogen and the solvent were trapped.

Upon further study, the inventors noted that low density and high-purity lead could be obtained from multiple cathode materials, regardless of cathode shape or relative movement of the solvent against the cathode. However, vigorous agitation or movement of the cathode relative to the electroprocessing solvent did simplify ‘harvest’ of the floating low density lead composition. Therefore, and among other suitable choices, preferred cathode materials include various metals, and especially aluminum. Alternatively, carbon (e.g. graphite, diamond like carbon, graphene, etc.,) matrices comprising at least one polymer and one form of carbon, Magneli Phase sub-oxides of titanimn (of the formula TixO(2x−1) where x is an integer between 4 and 11) have been discovered to be stable cathodes materials in the electroprocessing solvent and are contemplated for use as cathode surfaces.

While a lack of plating is typically undesirable in all or most electrowinning methods, the inventors now discovered that such lack of plating will enable a continuous lead recycling process in which lead can be continuously removed from the cathode on one segment while additional lead is formed on another segment of the cathode. Removal of the adherent/weakly associated lead is typically done using a mechanical implement (e.g., a wiping surface, blade, or other tool in close proximity to the cathode, etc.), however, removal can also be performed via non-mechanical tools (e.g., via jetting electroprocessing solvent against the cathode, or sparging gas against the cathode, etc.). Moreover, it should be noted that the removal may not use an implement at all, but merely by done by passive release of the low density lead material from the cathode and flotation to the surface of the electrochemical cell (where an overflow weir or harvesting will receive the lead materials).

Therefore, in at least some preferred aspects, the cathode comprises one or more disk-shaped aluminum cathodes that are rotatably coupled to the electrolytic cell and that are in close proximity to the cathode(s). FIG. 2A is an illustration of a small-scale experimental electrochemical device in which lead acid battery scrap materials (predominantly grid lead and active materials lead) are contacted in a digestion tank. Solid materials are then removed as needed and the lead ion enriched electroprocessing solvent is then fed into the electrolytic cell where low density lead materials are plated on the disk shaped electrode. As needed in the process, at least a portion of the electroprocessing solvent is fed to the recovery unit in which an ion exchange resin and a precipitation stage periodically remove sulfate ions and other non-metal ions. FIG. 2B is an illustration showing a more detailed view of a pair of disk-shaped cathodes and wiper surface that is proximally positioned to the cathodes to so wipe the low-density lead material from the cathode surface in a non-peeling manner (i.e., without lifting a coherent lead sheet or coherent lead film from the cathode in a pulling motion). FIG. 1C is more schematic exemplary depiction of an electrolyzer according to the inventive subject matter where electrolyzer 100 has a cell 110 that contains a lead ion-enriched electroprocessing solvent 112. Anode 120 and rotating disk-shaped cathode 130 are at least partially disposed in the cell to contact the lead ion-enriched electroprocessing solvent 112 and to promote formation of low density lead product 142 that is taken up by lead harvester 140 (typically a plastic wiper or otherwise proximally positioned surface). Most notably, the inventors realized that cell 110 can be operated without significant anodic destruction (e.g., less than 10% chelator loss per 12 hr continuous operation) of the chelator, even in the absence a membrane or other separator. Solvent conditioning unit 150 is fluidly coupled to the cell to receive solvent and provide back conditioned solvent.

Of course, it should be appreciated that the inventive subject matter is not limited to use of a disk-shaped electrode, but that in fact all electrodes are deemed suitable that allow active (e.g., using a wiping blade or surface) or passive removal (e.g., via bubbles, solvent jetting, or flotation) of high-purity lead from the cathode. Thus, suitable electrodes may be configured as simple plates that may be static relative to the solvent or moved in a reciprocal manner, or electrodes that can be continuously moved and that are configured to allow reduction of lead ions on one portion and lead removal on another portion. For example, suitable electrode configurations include conductive disks, cylinders, spheres, belts, etc. Likewise, it should be recognized that the number of cathodes may vary considerably, and that most typically multiple cathodes are operated in parallel (or serially, especially where the cathodes are static relative to the solvent.

Solvent processing can be performed in numerous manners and may be continuous or batch-wise. Most typically, processing the solvent includes a step of filtering to remove at least some of the particulates, a step of sulfate removal (e.g., via lime precipitation, reverse osmosis, ion exchange, electro-osmosis, salt splitting, liquid chromatography, liquid/liquid extraction etc.,), and/or a step of non-lead metal ion removal (e.g., ion exchange). Where the process is operated in a batch mode, collection of multiple streams of solvent is especially preferred, and a surge or holding tank may therefore be added to the system. On the other hand, where the system is continuously operated, multiple streams may be combined and then processed to reduce redundancy and plot space.

Lastly, with respect to the grid lead recovered from the lead ion-enriched solvent, it should be noted that the grid lead may be washed, compacted, and ingoted or be further refined to increase purity where desired. Residual plastic materials are preferably collected from the scrapping operation and recycled in a separate process stream using conventional plastic recycling methods.

Experimental Data and Considerations

All methods described herein can be performed in any suitable order unless otherwise indicated herein or otherwise clearly contradicted by context. The use of any and all examples, or exemplary language (e.g. “such as”) provided with respect to certain embodiments herein is intended merely to better illuminate the invention and does not pose a limitation on the scope of the invention otherwise claimed. No language in the specification should be construed as indicating any non-claimed element essential to the practice of the invention.

In a first set of experiments, the inventors investigated the ability of a solvent to digest various components of a lead acid battery and in a second set of experiments to investigate the ability to electroplate or reduce the dissolved lead (optionally after filtration). Digestion of the various components was initially carried out using only MSA in concentrations ranging from 1-50 wt %. At all concentrations the majority of the lead oxides were extremely soluble. However, the inventors did not attempt to isolate and test insoluble forms of PbO₂ in the initial work because it was quickly apparent that lead sulfate (PbSO4) did not digest very well. Although soluble, the overall concentration of lead sulfate was low (as measured by solution density), the rate of digestion was also slow (upwards of 24 hours), and digestion required agitation and heat. With the addition of disodium ethylenediamine tetraacetic acid (EDTA), both the concentration and digestion rate were vastly improved. The density increased from 1.2 g/cc to greater than 2.1 g/cc. More importantly and unexpectedly, lead was easily electroplated/reduced from this solution, in acid conditions and without the need for a membrane.

In a preferred set of experiments, the MSA concentration was approximately 25 wt % (+/−5) MSA in combination with approximately 5 wt % disodium EDTA. For example, a typical solution was made up as follows: 100 L of 98% MSA, 20 kg of Disodium EDTA, the remainder of water filled to 450 L total volume. However, the actual amounts used may vary by as much as 10%. Notably, this solution was able to digest approximately 33 kg of mixed battery materials in a 12 hour period without heating or significant agitation. The starting density was 1.1 g/cc and the maximum density achieved was 1.6 g/cc. It should be appreciated that some of the EDTA did not dissolve (possibly due to reaching saturation concentration in the acidic solution), and it is estimated that about 2 to 5 kg of the disodium EDTA did not fully dissolve and was captured as tank scaling or on the filters during recirculation. Therefore, in most practical examples, preferred electroprocessing solvents will include 20-30% MSA, 2-8% EDTA, with the remainder deionized water.

Remarkably, the bulk of lead oxide and sulfate are highly soluble in contemplated electroprocessing solvents while metallic lead (and solid lead alloys from lead grids) did not dissolve and was stripped clean of contamination; under most experimental conditions, 60-90% current efficiency was observed with a low voltage needed. Due to selective dissolving of the positive and negative active materials (PAM and NAM), substantially less energy for overall lead recycling is required.

Using a reclamation set up as shown in FIG. 2A, and a total swept cathode area of 0.252 m² and a tank size 10 US gallon, the following data in Table 1 and 2 were obtained:

TABLE 1 A/m2 Batch Run RPM Scraper A Cathode Vi Vf T 1 1 5.00 on 50.00 197.72 3.00 3.50 10.00 1 2 5.00 on 100.00 395.44 3.90 4.10 10.00 1 3 5.00 on 150.00 593.16 4.40 4.60 10.00 1 4 5.00 on 50.00 197.72 3.10 3.40 10.00 2 1 5.00 on 150.00 593.16 4.40 4.50 5.00 2 2 5.00 on 150.00 593.16 4.50 4.50 5.00 2 3 10.00 on 150.00 593.16 4.50 4.60 5.00 3 1 10.00 on 100.00 395.44 3.70 3.80 5.00 3 2 10.00 on 100.00 395.44 3.80 4.10 5.00 3 3 10.00 on 100.00 395.44 3.90 4.10 5.00 3 4 10.00 on 215.00 850.20 5.00 5.00 5.00 3 5 2.00 on 100.00 395.44 3.80 3.80 5.00 3 6 1.00 at end 93.00 367.76 3.80 3.80 5.00 3 7 1.00 at end 90.00 355.90 3.80 3.80 5.00 4 1 1.00 at end 400.00 1581.76 6.40 6.60 5.00 5 1 1.00 at end 200.00 790.88 4.60 4.60 5.00 5 2 on 200.00 790.88 4.80 4.80 5.00 5 3 on 200.00 790.88 4.70 4.70 5.00 5 4 on 200.00 790.88 4.80 4.80 5.00 5 5 on 200.00 790.88 4.60 4.60 6.20 5 6 on 200.00 790.88 4.70 4.70 5.00 5 7 on 200.00 790.88 4.70 4.70 5.00

TABLE 2 kg/h/ Pb (g/l) CE % Batch Run wet g dry g g/hr g/Ah m2 at start Theory 1 1 30.41 182.43 3.65 0.72 10.03 0.96 1 2 50.39 302.32 3.02 1.20 9.22 0.80 1 3 49.69 298.14 1.99 1.18 7.89 0.52 1 4 32.89 22.37 134.24 2.68 0.53 6.58 0.71 2 1 48.77 31.17 374.04 2.49 1.48 10.03 0.66 2 2 40.77 28.74 344.88 2.30 1.36 9.27 0.61 2 3 40.26 29.47 353.64 2.36 1.40 8.49 0.62 3 1 22.18 266.16 2.66 1.05 10.03 0.70 3 2 26.64 319.68 3.20 1.26 9.44 0.84 3 3 20.82 249.84 2.50 0.99 8.74 0.66 3 4 37.78 453.36 2.11 1.79 8.19 0.57 3 5 20.30 243.60 2.44 0.96 7.19 0.66 3 6 12.70 152.40 1.64 0.60 6.66 0.43 3 7 10.38 124.56 1.38 0.49 6.32 0.36 4 1 56.79 681.48 1.70 2.69 10.03 0.45 5 1 33.80 405.60 2.03 1.60 10.03 0.53 5 2 34.50 414.00 2.07 1.64 9.12 0.55 5 3 30.48 365.76 1.83 1.45 8.31 0.48 5 4 28.40 340.80 1.70 1.35 7.56 0.45 5 5 31.70 306.77 1.53 1.21 6.73 0.40 5 6 22.90 274.80 1.37 1.09 6.12 0.36 5 7 20.50 246.00 1.23 0.97 5.58 0.32 Efficiencies for plating are depicted in FIGS. 3A-3C, wherein FIG. 3A shows the current efficiency of lead production as a function of the initial lead concentration at 200 A at a current density of 790 A/m² and 1 rpm of the disk cathode. FIG. 3B shows the current efficiency as a function of electrode current density, and FIG. 3C plotted current efficiency against lead concentration.

As is shown in Table 3 below, high purity lead was obtained at the cathode as a micro- or nanoporous mixed matrix having a density of less than 1 g/cm³ (floating on the surface of the solvent). Moreover, the lead composition did not plate on the cathode as a solid and coherent film but was recovered as amorphous soft and compressible mixed material that contained the methane sulfonic acid and hydrogen.

TABLE 3 Element Quant. Det. Limit Actual Bismuth ppm, (μg/g) 0.1 1.3 Copper ppm, (μg/g) 0.1 1.1 Lead ppm, (μg/g) 0.1 Major (99.5%+) Potassium ppm, (μg/g) 0.5 18 Sodium ppm, (μg/g) 0.1 0.20 Tin ppm, (μg/g) 0.2 30

Notably, the so obtained mixed material was different from conventional sponge lead that is normally produced using foaming agents or gas injection during cooling of liquid lead that was previously purified.

It should be apparent to those skilled in the art that many more modifications besides those already described are possible without departing from the inventive concepts herein. The inventive subject matter, therefore, is not to be restricted except in the spirit of the appended claims. Moreover, in interpreting both the specification and the claims, all terms should be interpreted in the broadest possible manner consistent with the context. In particular, the terms “comprises” and “comprising” should be interpreted as referring to elements, components, or steps in a non-exclusive manner, indicating that the referenced elements, components, or steps may be present, or utilized, or combined with other elements, components, or steps that are not expressly referenced. Where the specification claims refers to at least one of something selected from the group consisting of A, B, C . . . and N, the text should be interpreted as requiring only one element from the group, not A plus N, or B plus N, etc. 

What is claimed is:
 1. A method of processing lead materials from lead acid batteries, comprising: providing lead materials comprising grid lead and active material lead, wherein the active material lead comprises lead sulfate, and contacting the lead materials with an electroprocessing solvent to selectively dissolve the active material lead to so form a lead ion-enriched electroprocessing solvent and solid grid lead; wherein the electroprocessing solvent is an aqueous solution of an alkane sulfonic acid and a chelator having a pH of less than 7; removing at least some of the grid lead from the lead ion-enriched electroprocessing solvent; reducing lead ions in the lead ion-enriched electroprocessing solvent on a cathode to form adherent high-purity lead and regenerated electroprocessing solvent; and wherein the steps of providing lead materials, contacting the lead materials, removing at least some of the grid lead, and reducing lead ions are performed to allow processing in a continuous fashion.
 2. The method of claim 1 wherein the active material lead is not previously desulfurized.
 3. The method of claim 1 wherein the electroprocessing solvent comprises the alkane sulfonic acid in an amount of between 5 and 50 wt % and the chelator in an amount of between 0.5 and 20 wt %.
 4. The method of claim 1 wherein reducing the lead ions is performed concurrently with a further step of removing at least some of the adherent high-purity lead from the cathode.
 5. The method of claim 1 wherein reducing the lead ions is performed under conditions that form a micro- or nanoporous mixed matrix having a density of less than 5 g/cm³.
 6. The method of claim 1 wherein the cathode is moved relative to the lead ion-enriched electroprocessing solvent during the step of reducing the lead ions.
 7. The method of claim 1 further comprising a step of removing sulfate and/or a metal ion other than lead from the regenerated electroprocessing solvent.
 8. The method of claim 1 further comprising a step of using at least some of the regenerated electroprocessing solvent in the step of contacting the lead materials with the electroprocessing solvent. 